Improving Machining Accuracy of the EMM Process through Multi-Physics Analysis

Abstract:

Article Preview

In this study, the parametric effects of the EMM process were studied by both numerical simulation and experimental tests. The numerical simulation was performed using commercial software, FEMLAB, to establish a multi-physics model which consists of electrical field, convection and diffusion phenomena to simulate the parametric effects of pulse rate, pulse duty, electrode gap and inflow velocity. From the simulated results, the relationship between parameters and the distribution of metal removal could be established. Proper process variables were also chosen to conduct the EMM experiments. After the experiments, the profile of the processed rectangular slot was measured by a Keyence digital microscope. Comparing profile of the processed rectangular slot with the profile of the cathode, the machining accuracy of EMM process could be determined. It could also verify the goodness of the multi-physics model for predicting machining accuracy. From this study, the effects of parameters such as pulse rate, pulse duty, electrode gap and inflow velocity are better understood. The simulation model could be employed as a predictive tool to provide optimal parameters for better machining accuracy and process stability of the EMM process.

Info:

Periodical:

Key Engineering Materials (Volumes 364-366)

Edited by:

Guo Fan JIN, Wing Bun LEE, Chi Fai CHEUNG and Suet TO

Pages:

290-296

Citation:

S. J. Lee et al., "Improving Machining Accuracy of the EMM Process through Multi-Physics Analysis", Key Engineering Materials, Vols. 364-366, pp. 290-296, 2008

Online since:

December 2007

Export:

Price:

$38.00

[1] M. Datta and D. Harris: Electrochimica Acta Vol. 42 (1997), p.3007.

[2] M. Datta and D. Landolt: Electrochimica Acta Vol. 45 (2000), p.2535.

[3] M. Ghaemi and L. Binder: Journal of power source Vol. 111 (2002), p.248.

[4] B. Bhattacharyya and J. Munda: International Journal of Machine Tools & Manufacture Vol. 43 (2003), p.1301.

[5] M. Kock, V. Kirchner and R. Schuster: Electrochimica Acta Vol. 48 (2003), p.3213. Fig. 9 The profile of the slot processed by the EMM process with pulse A A B B.

[6] C. Rosenkranz, M.M. Lohrengel and J.W. Schultze: Electrochimica Acta Vol. 50 (2005), p. (2009).

[7] B. Bhattacharyya, M. Malapati and J. Munda: Journal of Materials Processing Technology Vol. 169 (2005), p.485.

[8] B. Bhattacharyya, B. Doloi and P.S. Sridhar: Journal of Materials Processing Technology Vol. 113 (2001), p.301.

[9] A.K.M.D. Silva and J.A. Mcgeough: Journal of Material Processing Technology Vol. 76 (1998), p.165.

[10] W. Ehrfeld: Electrochimica Acta Vol. 48 (2003), p.2857.

[11] H. Hocheng, Y.H. Sun, S.C. Lin and P.S. Kao: Journal of Material Processing Technology Vol. 140 (2003), p.264.

Fetching data from Crossref.
This may take some time to load.